Sierra Space confirms burst test of its fullscale inflatable module was successful

Sierra Space yesterday confirmed that the pressure test-to-failure of a fullscale inflatable space station module was successful in proving its safety and design.

The pressure shell for Sierra Space’s LIFE™ (Large Integrated Flexible Environment) habitat is made of expandable “softgoods,” or woven fabrics that perform like a rigid structure once inflated. During an Ultimate Burst Pressure (UBP) test, the teams inflate the test article until it fails, which helps determine how strong its softgoods materials would be under extreme stresses in the harsh environment of space. The full-scale unit in this test reached 77 psi before it burst, which well exceeds (+27%) NASA’s recommended level of 60.8 psi (maximum operating pressure of 15.2 psi multiplied by a safety factor of four).

A short video showing the moment the module bursts can be seen here.

The module is for the Orbital Reef commercial space station that Sierra Space is building in partnership with Blue Origin, which is supposed to be the lead company in the project. However, it is Sierra Space that appears to be building and testing hardware. What Blue Origin is doing remains unclear, as has been the case now for five-plus years.

Orbital Reef partnership between Blue Origin and Sierra Space in trouble

According to anonymous sources, CNBC reports that the partnership between Blue Origin and Sierra Space to build the private commerical Orbital Reef space station is possibly breaking up.

The companies announced Orbital Reef as a co-led project in 2021, but updates about the project dried up in the past year. The pair of private space companies are now navigating a potential end to the Orbital Reef partnership, according to three people who spoke to CNBC about the situation.

Those people, speaking on the condition of anonymity to discuss nonpublic matters, emphasized that discussions are ongoing and described the situation as fluid. But other development projects with more significant current contracts – such as Blue Origin’s Blue Moon lunar lander and Sierra Space’s Dream Chaser spaceplane – have taken higher priority for both companies, those people said.

To readers of Behind the Black, this possible break-up is not a surprise. In June Sierra’s announcement of its own independent space station based on its LIFE modules suggested it had its own doubts about Orbital Reef. Then in August, when Sierra announced a partnership with Redwire to launch LIFE as an independent station, I wrote this:

What struck me about this deal is the shrinking mention of Blue Origin. Originally that company was listed as one of the major players in building this private space station, dubbed Orbital Reef, in which LIFE is only the first module. In the past year however its participation seems less and less significant in every subsequent press release. It appears to still be part of the project, but it is Sierra Space that is leading the effort, and appears to be making things happen.

But then, the track record of Blue Origin is to not make things happen. It could very well be that events are once again overtaking it. Sierra Space can’t wait for Blue Origin to slowly get its act together. It is finding ways to get things done, even if that means Blue Origin gets left behind.

Today’s CNBC story reinforces this conclusion. So does its timing with the removal of Blue Origin’s CEO, Bob Smith, earlier this week. It could be that the failure of Blue Origin in the Orbital Reef partnership was the final straw for Jeff Bezos.

The problem for NASA in this is that the agency awarded a $130 million contract to the Orbital Reef partnership, with Blue Origin listed as the lead contractor which controls the contract. If that partnership ends, that contract must get renegotiated or cancelled, or gets transferred from Blue Origin to Sierra Space (the most likely outcome).

Redwire to build biotech lab in Sierra Space’s LIFE space station

Sierra Space announced yesterday that — as part of its private space station module dubbed LIFE — it is partnering with Redwire to install a commercial biotech lab in the module.

The hardware includes equipment that Redwire has previously developed for the International Space Station, such as the Advanced Space Experiment Processor, which hosts biotech experiments. A particular focus will be on crystallization experiments, using the microgravity environment to grow larger crystals that can then be studied to determine their structure for pharmaceutical applications.

The companies did not disclose terms of the contract other than that Redwire will start delivering hardware in the fourth quarter of this year. Gold said that the companies will also partner on business development to identify customers for using the experiment platform.

The target date for the launch of LIFE is presently 2026, though it was not revealed when Redwire’s equipment would be installed.

What struck me about this deal is the shrinking mention of Blue Origin. Originally that company was listed as one of the major players in building this private space station, dubbed Orbital Reef, in which LIFE is only the first module. In the past year however its participation seems less and less significant in every subsequent press release. It appears to still be part of the project, but it is Sierra Space that is leading the effort, and appears to be making things happen.

But then, the track record of Blue Origin is to not make things happen. It could very well be that events are once again overtaking it. Sierra Space can’t wait for Blue Origin to slowly get its act together. It is finding ways to get things done, even if that means Blue Origin gets left behind.

Sierra Space says first Dream Chaser will be ready for launch by December

In a presentation at an investor conference on June 27, 2023, a Sierra Space official provided an update on the status of its first Dream Chaser reusable mini-shuttle, dubbed Tenacity, stating that they expect it to be ready for launch by December, with the main question whether its ULA Vulcan launch rocket will also be ready.

The launch is supposed to be the second for Vulcan, but the first launch was just delayed for an undetermined amount of time so ULA can make modifications to the rocket’s Centaur upper stage. Once Tenacity is flying Sierra has a contract with NASA for seven cargo flights to ISS, with plans beyond.

The company is also working on a second version that can carry both crew and cargo. Vice said that version will have 40% greater cargo capacity than the first version and can support a six-person crew.

The ability of Dream Chaser to glide back to Earth in a runway landing, rather than splash down in the ocean, is a key selling point to customers, he argued. “We just think that landing at runways around the world is a huge differentiator: low-g landing back on a runway for both time-critical cargo and science, but also just the way people are going to want to fly back and land.”

The official also indicated that this human-rated version is being designed to work with the private Orbital Reef space station that Sierra Space is building in partnership with other companies. The company also said it is planning its own free flying version of its Orbital Reef LIFE module that the company hopes to launch by the end of 2026, ahead of Orbital Reef. If so, that would make this the sixth independent private space station planned by American companies.

Because much of this presentation was designed to impress potential investors, we should take it with a touch of skepticism. Nonetheless, that the company is considering launching its own station, independent of the Blue Origin-led Orbital Reef station, suggests it has its own doubts about whether that project will ever take off as planned, and has thus decided to make its own contingency plans.

Hat tip to Jay, BtB’s stringer.

ILC Dover to provide spacesuits and “softgoods” for Sierra Space’s LIFE space station

Sierra Space yesterday announced that it has signed a partnership deal with ILC Dover for it to provide spacesuits and other “softgoods” for Sierra Space’s LIFE space station, including helping to build the station’s inflatable modules.

ILC Dover will be an exclusive partner with Sierra Space for softgoods used to support inflatable space habitat systems for low-Earth orbit (LEO), lunar and Mars transport and surface habitation, and use cases even farther into deep space.

The two companies have already been working together on the development and testing of Sierra Space’s first prototype inflatable modules.

Sierra Space pops another inflatable test space station module

Proposed Orbital Reef space station
Proposed Orbital Reef space station

Sierra Space announced yesterday that it had successfully completed its fourth test to failure of a one-third scale prototype inflatable space station module, dubbed LIFE, with work on the full scale module expected to begin next year and leading to the launch of its private commercial space station sometime later this decade.

In February, Sierra Space performed a month-long Accelerated Systematic Creep (ASC) test on LIFE – the first milestone in its 2023 testing campaign. Engineers loaded a one-third-scale version of the inflatable habitat with a sustained amount of pressure over an extended period until it failed. Per NASA’s recommended guidelines for inflatable softgoods certification, the test reached its goal of generating an additional data point – pressure and time to burst – which can be used to estimate the life of the primary pressure shell structure.

“Our testing campaign has demonstrated that our LIFE habitat pressure shell design has a predicted life of far greater than 60 years – or 525,600 hours – based on Sierra Space’s 15-year on-orbit life requirement and the applied 4x safety factor,” said Sierra Space Chief Engineer for LIFE, Shawn Buckley. “We are obviously simulating pressures well in excess of the norm.”

You can view video of the test here. The failure was so intense that it also blew up the test shack.

Sierra Space is part of a partnership with Blue Origin and others to build the Orbital Reef space station, one of four such stations with contracts with NASA. Sierra Space is building the station’s modules, while Boeing is providing the Starliner capsule for transportation. Blue Origin is supposed be providing larger modules and the New Glenn rocket for transportation, but the development of both continues to lag.

September 13, 2022 Quick space links

Courtesy of stringer Jay.

Sierra Space signs partnership deal with Turkey

Sierra Space and ESEN (another affiliated company of Sierra Space’s mother company Sierra Nevada) have signed a partnership agreement with the Turkish Space Agency to work together over the next five years in developing Sierra Space’s Dream Chaser spacecraft and its LIFE orbital space station.

Though the agreement mentions how the three will work together to develop both Dream Chaser and LIFE, because of State department security regulations Sierra Space must be very careful about what technology it reveals to Turkey. I therefore expect the heart of the agreement are these two bullet points from the press release:

  • Space environment utilization on-orbit in LEO, including use of Sierra Space’s Large Integrated Flexible Environment (LIFE) space habitat module
  • Sending payloads to low Earth orbit (LEO) and the moon

Turkey wants to launch its own planetary probes as well as astronauts in order to compete with its Middle East neighbor the UAE. It has thus decided to pay Sierra Space to help it do that. The company can use the cargo Dream Chaser to lift smallsat payloads into orbit, and later use the manned version to lift Turkish astronauts to the LIFE station.

NASA awards contracts to three private space station projects

Capitalism in space: NASA today announced development contract awards to three different private space station projects.

  • Nanoracks Starlab concept won $160 million. Partners include Voyager Space and Lockheed Martin.
  • Blue Origin’s Orbital Reef project was awarded $130 million, partnering with Sierra Space, Boeing, and Redwire.
  • Northrop Grumman won $125.6 million on a concept based on upgrades to its Cygnus freighter.

All three contracts are Space Act agreements, designed by NASA to jumpstart the companies and their design efforts. All three are in addition to the effort by Axiom to build its own ISS modules that will eventually detach to form its own independent station.

That’s four private American space stations now in the works. All are aiming to launch before this decade is out.

Sierra Space raises $1.4 billion in investment capital

Capitalism in space: Sierra Space, the space subsidiary of Sierra Nevada, has raised $1.4 billion in investment capital in a recent round of fund-raising.

The company will use the funds to support development of Dream Chaser, the lifting-body vehicle it is building for to transport cargo for the International Space Station starting in late 2022. The company originally developed Dream Chaser to carry people as a competitor in NASA’s commercial crew program, and company executives have frequently stated they still plan to develop a crewed version at a later date.

The funds will also support development of its Large Integrated Flexible Environment (LIFE) inflatable module. Both LIFE and Dream Chaser are part of Orbital Reef, the commercial space station concept announced Oct. 25 by a team that includes Sierra Space along with Blue Origin, Boeing and Redwire.

It appears that the investment community likes the Orbital Reef commercial space station concept, and especially likes Sierra Space’s part in it. This influx of cash also suggests that the investors got a good look at the status of Dream Chaser, and were satisfied its development was proceeding as planned.

Where to find life in the Milky Way galaxy

A paper published today on the Los Alamos astro-ph preprint website has attempted to model the habitable zones within the Milky Way galaxy. From the abstract:

We predict that ~1.2% of all stars host a planet that may have been capable of supporting complex life at some point in the history of the Galaxy. Of those stars with a habitable planet, ~75% of planets are predicted to be in a tidally locked configuration with their host star. The majority of these planets that may support complex life are found towards the inner Galaxy, distributed within, and significantly above and below, the Galactic midplane.[emphasis mine]

They took into consideration the hazard of supernovae for killing off planetary life, as well as other factors such as the where the necessary heavier elements would be available for producing planets.

You can download the paper here [pdf].

First planet discovered that might harbor life!

Big news! Scientists have discovered the first rocky terrestrial planet orbiting its sun at a distance where life as we know it could form. The planet itself has a mass three to four times Earth, so no matter what, conditions on its surface would be very different than here. Nonetheless, this is a major discovery, and is only the first of many. Key quote:

The discovery suggests habitable planets must be common, with 10 to 20 per cent of red dwarfs and sun-like stars boasting them, the team says. That’s because Gliese 581 is one of just nine stars out to its distance that have been searched with high enough precision to reveal a planet in the habitable zone.